Deposition of protective material at wafer level in front end for early stage particle and moisture protection

ABSTRACT

A semiconductor device and a method of manufacturing the same are provided such that a microelectromechanical systems (MEMS) element is protected at an early manufacturing stage. A method for protecting a MEMS element includes: providing at least one MEMS element, having a sensitive area, on a substrate; and depositing, prior to a package assembly process, a protective material over the sensitive area of the at least one MEMS element such that the sensitive area of at least one MEMS element is sealed from an external environment, where the protective material permits a sensor functionality of the at least one MEMS element.

FIELD

The present disclosure relates generally semiconductor devices and amethod of manufacturing the same, and, more particularly, to depositionof protective material at a wafer level in a front end process for earlystage protection.

BACKGROUND

During fabrication of a semiconductor device, a wafer serves as asubstrate for microelectronic devices built in and over the wafer andmay undergo many microfabrication process steps such as doping or ionimplantation, etching, deposition of various materials, andphotolithographic patterning. Finally, the individual microcircuits areseparated (dicing) and packaged.

Microelectromechanical systems (MEMS) is a technology of microscopicdevices, particularly those with moving parts. MEMS became practicalonce they could be fabricated using modified semiconductor devicefabrication technologies, normally used to make electronics. Thus, aMEMS may be built into a substrate as a component of an integratedcircuit, that is diced into a semiconductor chip that is subsequentlymounted in a package.

A protective material may be dispensed extensively all over thesemiconductor chip and package at the end of the assembly process (i.e.,filling of a cavity within the package). In some cases, particleprotection is realized via a lid construction that is disposed over anopening of the package.

When a protective material is dispensed at the end of the assemblyprocess, particles from a preassembly processes (i.e., prior to mountingthe chip to the package) or a foregoing assembly process can reach thesurface of a MEMS element or device. While miniaturization of MEMSelements evolves, smaller and smaller particles are playing a role, andare at the same time becoming more difficult to detect and screen.Furthermore, using a lid for particle protection does not provideabsolute protection from humidity.

SUMMARY

A semiconductor device and a method of manufacturing the same areprovided such that a microelectromechanical systems (MEMS) element isprotected at an early manufacturing stage.

Embodiments provide a method for protecting a MEMS element, includingproviding at least one MEMS element, having a sensitive area, on asubstrate; and depositing, prior to a package assembly process, aprotective material over the sensitive area of the at least one MEMSelement such that the sensitive area of at least one MEMS element issealed from an external environment, where the protective materialpermits a sensor functionality of the at least one MEMS element.

Embodiments further provide a semiconductor device including asemiconductor chip. The semiconductor chip includes a substrate; atleast one MEMS element, having a sensitive area, disposed on thesubstrate; a protective material disposed over the sensitive area of theat least one MEMS element such that the sensitive area of at least oneMEMS element is sealed from an external environment, where theprotective material is configured to permit a sensor functionality ofthe at least one MEMS element; and a package to which the semiconductorchip is mounted.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are described herein making reference to the appendeddrawings.

FIG. 1 shows a cross-sectional diagram of a wafer at a front-end stageof a chip fabrication process according to one or more embodiments;

FIG. 2 shows a cross-sectional diagram of another wafer during apreassembly stage of a chip fabrication process according to one or moreembodiments;

FIG. 3 shows a cross-sectional diagram of a chip according to one ormore embodiments;

FIG. 4 shows a cross-sectional diagram of another chip according to oneor more embodiments;

FIG. 5 shows a cross-sectional diagram of still another chip accordingto one or more embodiments;

FIG. 6A shows a cross-sectional diagram of still another chip accordingto one or more embodiments;

FIG. 6B shows a plan view of a lid structure shown in FIG. 6A accordingto one or more embodiments.

FIG. 7 shows a cross-sectional diagram of still another chip accordingto one or more embodiments;

FIG. 8 shows a cross-sectional diagram of a package according to one ormore embodiments; and

FIG. 9 shows a cross-sectional diagram of a package with a seal ringaccording to one or more embodiments.

DETAILED DESCRIPTION

In the following, various embodiments will be described in detailreferring to the attached drawings, where like reference numerals referto like elements throughout. It should be noted that these embodimentsserve illustrative purposes only and are not to be construed aslimiting. For example, while embodiments may be described as comprisinga plurality of features or elements, this is not to be construed asindicating that all these features or elements are needed forimplementing embodiments. Instead, in other embodiments, some of thefeatures or elements may be omitted, or may be replaced by alternativefeatures or elements. Additionally, further features or elements inaddition to the ones explicitly shown and described may be provided, forexample conventional components of sensor devices.

Features from different embodiments may be combined to form furtherembodiments, unless specifically noted otherwise. Variations ormodifications described with respect to one of the embodiments may alsobe applicable to other embodiments. In some instances, well-knownstructures and devices are shown in block diagram form rather than indetail in order to avoid obscuring the embodiments.

Connections or couplings between elements shown in the drawings ordescribed herein may be wire-based connections or wireless connectionsunless noted otherwise. Furthermore, such connections or couplings maybe direct connections or couplings without additional interveningelements or indirect connections or couplings with one or moreadditional intervening elements, as long as the general purpose of theconnection or coupling, for example to transmit a certain kind of signalor to transmit a certain kind of information, is essentially maintained.

Embodiments relate to microelectromechanical systems (MEMS), andparticularly to a MEMS pressure sensor integrated on a semiconductorchip and subsequently mounted to a package. The MEMS may be referred toas a MEMS element or MEMS device. The package is adapted to enable theMEMS pressure sensor to detect and/or measure a force imposed thereon.For example, the MEMS pressure sensor may operate as a transducer thatgenerates an electrical signal as a function of the pressure imposed,and the package may have an opening formed in proximity to the MEMSpressure sensor that allows a medium to interact with the MEMS pressuresensor. The medium may be any pressure measurable or pressure inducingentity.

In general, a sensor, as used herein, may refer to a component whichconverts a physical quantity to be measured to an electric signal, forexample a current signal or a voltage signal. The physical quantity may,for example, be pressure as an expression of force imposed on asensitive area or region of the sensor. Debris, such as foreignparticles, may negatively impact the performance of any sensor. Thus, itis desirable to prevent debris from reaching the surface of the sensor,and, specifically, from reaching the sensitive area or region of thesensor.

A manufacturing process for semiconductor chip fabrication may includetwo sequential sub-processes commonly referred to as front-end andback-end production. The back-end production may further include twosequential sub-processes commonly referred to as pre-assembly andassembly.

Front-end production refers primarily to wafer fabrication. A wafer, asused herein, may also be referred to as a substrate. The front-endproduction may start with a clean disc-shaped silicon wafer that willultimately become many silicon chips. First, a photomask that definesthe circuit patterns for circuit elements (e.g., transistors) andinterconnect layers may be created. This mask may then be laid on theclean silicon wafer and is used to map the circuit design. Transistorsand other circuit elements may then be formed on the wafer throughphotolithography. Photolithography involves a series of steps in which aphotosensitive material is deposited on the wafer and exposed to lightthrough a patterned mask; unwanted exposed material is then etched away,leaving only the desired circuit pattern on the wafer. By stacking thevarious patterns, individual elements of the semiconductor chip may bedefined. A MEMS device or MEMS element may also be incorporated ontoand/or into the surface of the wafer and connected to one or morecircuit elements. During the final phase of the front-end productionprocess, each individual chip on the wafer is electrically tested toidentify properly functioning chips for assembly.

Back-end production refers to the assembly and test of individualsemiconductor devices or chips. The assembly process is intended toprotect the chip, facilitate its integration into electronic systems,limit electrical interference and enable the dissipation of heat fromthe device. Once the front-end production process is complete, the waferis sawed or diced into individual semiconductor chips. This dicing ofthe wafer into individual semiconductor chips is referred to aspre-assembly.

In an assembly phase of the back-end production, the semiconductor chipsare incorporated into a package. For example, these semiconductor chipsmay be individually attached by means of an alloy or an adhesive to alead frame, a metallic device used to connect the semiconductor to acircuit board. Leads on the lead frame may then be connected by aluminumor gold wires to the input/output terminals on the semiconductor chipthrough the use of automated machines known as wire bonders. Eachsemiconductor device may then be at least partially encapsulated in aplastic molding compound or ceramic case, forming the package.

Thus, a MEMS element may be built into a substrate as a component of anintegrated circuit, the substrate then being diced into semiconductorchips that are each subsequently mounted in a package.

It will be appreciated that while the pre-assembly (i.e., dicing)process may be described as part of the back-end production, the chipsmay be partially singulated during final phase of the front-endproduction. Thus, in some instances, pre-assembly may begin or may beperformed during the front-end production.

According to one or more embodiments, a protective material (e.g., asilicone gel) is deposited on a MEMS element at the wafer level (i.e.,during the front-end production process), or during or subsequent to thepre-assembly process, but prior to assembly (i.e., packaging). Theprotective material may be deposited on an exposed surface of the MEMSelement such that an entire exposed surface of the MEMS element iscovered by the protective material.

The exposed surface of the MEMS element may include or may be referredto as a sensitive area that enables the MEMS element to measure aphysical quantity. For example, the MEMS element may be a MEMS pressuresensor that is configured to detect or measure a change in pressure inresponse to a change of force imposed on the exposed surface. Theprotective material is configured such that, when the MEMS element iscovered by the protective material, a sensor functionality of the MEMSelement remains intact. For example, the protective material may be asilicone gel that has an elastic modulus and/or a Poisson's ratio thatpermits a force exerted thereon to be transferred to the MEMS pressuresensor. Thus, the protective material is flexible enough that when theprotective material is depressed, the sensitive area of the MEMSpressure sensor is also depressed proportionally.

More particularly, the protective material permits full sensorfunctionality of the MEMS element, including mechanical functionalityand electrical functionality, while sealing an entire surface of theMEMS element. Even more particularly, the protective material isconfigured such that no functionality of the MEMS element is impeded bythe protective material.

By ensuring that the functionality of the MEMS element remains intact,the protective material may be deposited onto the MEMS element as apermanent material at an early stage of the chip fabrication process.Thus, the MEMS element may already be configured in an operable state(e.g., a final operable state) at the time the protective material isdeposited onto the MEMS element, and the protective material may remaincompletely intact after deposition, including throughout the assemblyprocess, such that it remains a feature in the final product.

As a result of the early deposition of the protective material, the MEMSelement is provided early particle and humidity protection from foreignmatter that may have been introduced during (pre-)assembly processesthat could influence the sensor performance.

While some embodiments provided herein may refer to the protectivematerial as being a temperature hardening gel (e.g., silicone gel),others may use a ultraviolet (UV) hardening gel. However, the protectivematerial is not limited thereto, and may be any material that providesprotection from foreign matter while permitting sensor functionality ofthe MEMS element, and more particularly permits sensor functionality ofthe MEMS element at the time of deposition of the protective material.Thus, the protective material may be any temperature or UV hardeninggel.

FIG. 1 shows a cross-sectional diagram of a wafer at a front-end stageof a chip fabrication process according to one or more embodiments. Thewafer is a substrate 10 that includes a main surface 11 and MEMSelements 12 provided thereon. Each of the MEMS elements 12 may beembedded into the substrate 10 on the main surface 11 of the substrate10 with a surface (e.g., upper surface as shown) exposed. Further, eachof the MEMS elements 12 may correspond to a single chip formed at asubsequent step of the chip fabrication process. However, it will beappreciated that a chip may include multiple MEMS elements integratedthereon.

The exposed surface of the MEMS element 12 may be or may include asensitive area configured to detect a physical quantity, such aspressure, such that the physical quantity can be measured. After theMEMS element 12 is provided on the substrate 10, a protective material13 may be deposited locally, for example, in the form of small droplets,on each MEMS element 12, and then cured (e.g., thermal curing at about150° C.). The protective material 13 is deposited locally such that theexposed surface of each MEMS element 12 is covered by the protectivematerial 13. More particularly, the protective material 13 is depositedlocally such that the sensitive area of each MEMS element 12 is coveredby the protective material 13. Thus, it can be said that the protectivematerial 13 is deposited as a locally defined droplet confined to alocal region of the substrate 10 that surrounds each MEMS element 12.

The protective material 13 is deposited locally in manner such that bondpads of a “to be” chip corresponding to the MEMS element are not coatedby the protective material 13. One possible method for depositing thelocally positioned droplets of protective material 13 is by inkjetprinting or micro dispensing. However, the embodiments are not limitedto a particular method for depositing the protective material 13.

In view of the above, each MEMS element 12 is sealed at its uppersurface from an external environment that may protect the MEMS element12 from particles and humidity that may contaminate the MEMS element 12.Furthermore, the protective material 13 is composed of a material (e.g.,temperature hardening gel or UV hardening gel) that permits a sensorfunctionality of the each MEMS element 12. More particularly, protectivematerial 13 permits full sensor functionality of the MEMS element,including mechanical functionality and electrical functionality, whilesealing an entire (upper) surface of each MEMS element 12.

FIG. 2 shows a cross-sectional diagram of another wafer during anotherstage of a chip fabrication process according to one or moreembodiments. In particular, the protective material 13 (i.e., thelocally dispensed droplets) is dispensed after a preassembly process.Specifically, the protective material 13 is dispensed after theindividual chips 14 are formed, but prior to an assembly process (i.e.,a package assembly process).

Here, the wafer substrate 10 may be attached to a foil layer 15 and thechips 14 are singulated by a sawing process or dicing process.Subsequent to forming the individual chips 14, the protective material13 may be dispensed in a controlled manner over each of the MEMSelements 12. A UV hardening gel may be used as the protective material13 since the foil layer 15 may not withstand heat used in the curingprocess. Thus, protective materials that are cured by thermal curing mayneed to be avoided according to the use of the foil layer 15.

It will also be appreciated that a single chip 14 may include multipleMEMS elements 12, as will be discussed in conjunction with otherexamples below.

FIG. 3 shows a cross-sectional diagram of a chip 34 according to one ormore embodiments. The chip 34 includes a substrate 10 having a mainsurface 11 and multiple MEMS elements 12 provided thereon. It will beappreciated that, while multiple MEMS elements 12 are shown, the chip 34may be include a single MEMS element 12.

The chip 34 further includes a stress-decoupling feature made of one ormore deep trenches 16 (i.e., one or more stress-decoupling trenches) anda backside cavity 19 that is integrally formed with the one or moretrenches 16. The trenches 16 and backside cavity 19 may be formed toestablish a spring structure surrounding the MEMS element 12 whichdecouples the MEMS elements 12 from stress coming from the package orthe rest of the chip. Thus, a stress-decoupling feature prevents a shiftin a sensor signal produced by one or more of the MEMS elements 12 dueto external mechanical influences.

Each trench 16 is laterally spaced from each outer MEMS element 12 andextends into the substrate 10. The protective material 13 is dispensedin a controlled manner such that the exposed surfaces of the MEMSelements 12 are covered by the protective material 13. The protectivematerial 13 may be dispensed as a single droplet or as multiple dropletsthat cover a local region, including the MEMS elements 12.

Furthermore, the protective material 13 may be configured to stop at aninside edge of each trench 16 such that the protective material 13 doesnot enter the trench 16. In particular, the protective material 13 isconfined to an area within a region defined by the one or more trenches16. The protective material 13 may stop at 90° to the edge of eachtrench 16. For example, a viscosity of the protective material 13 incombination with controlled placement of the protective material 13 mayallow the protective material 13 to stop flowing prior to entering atrench 16.

It will also be appreciated that, similar to the protective material 13described in conjunction with FIG. 2, the protective material 13 shownin FIG. 3 also permits full sensor functionality of each MEMS element 12while sealing those MEMS elements 12 from the external environment.

FIG. 4 shows a cross-sectional diagram of another chip 44 according toone or more embodiments. The chip 44 includes a substrate 10 having amain surface 11 and multiple MEMS elements 12 provided thereon. It willbe appreciated that, while multiple MEMS elements 12 are shown, the chip44 may be include a single MEMS element 12.

The chip 44 further includes at least one stop frame 17 provided on thesubstrate 10 at a region that surrounds the MEMS elements 12 such thatthe stop frame 17 is configured to confine the protective material 13inside the region. That is, the stop frame 17 acts as a dam for theprotective material 13.

The chip 44 may contain more than one MEMS areas, where each MEMS areaincludes one or more MEMS elements 12. Each MEMS area may be at leastpartially surrounded by a stop frame. Thus, multiple MEMS areas on thesame chip surrounded a respective stop frame 17 may be provided.

The stop frame 17 may comprise any material that is suitable to bestructured and/or locally deposited as a frame. For example, the stopframe 17 may comprise imide, SU-8 photoresist, silicone, or other likematerial. A material of the stop frame 17 may have a higher degree ofelastic modulus than the protective material 13, but may also have adegree of elastic modulus that is equal to or lower than the elasticmodulus of the protective material 13, so long as the material of thestop frame 17 is capable of being structured into a frame and able toconfine the protective material 13 to a region.

The stop frame 17 may be formed in order to prevent the protectivematerial 13 from flowing to another part of the chip 44 that is intendedto remain free of the protective material 13. For example, the stopframe 17 may be used to prevent the protective material 13 from flowingonto bond pads (not shown) of the chip 44. In another example, the stopframe 17 may be provided at or in proximity to an inner edge of one ormore trenches 16 in order to prevent the protective material 13 fromentering the one or more trenches 16.

Thus, the stop frame 17 may be formed prior to the deposition of theprotective material 13 to contain the protective material 13 to aspecific region of the chip 44. Furthermore, the stop frame 17 may beremoved subsequent to curing the protective material 13.

In addition, a backside cavity 19 may be formed at the backside of thesubstrate 10 as an additional stress-decoupling feature that isintegrally formed with the one or more trenches 16.

FIG. 5 shows a cross-sectional diagram of still another chip 54according to one or more embodiments. The chip 54 includes a substrate10 having a main surface 11 and multiple MEMS elements 12 providedthereon. It will be appreciated that, while multiple MEMS elements 12are shown, the chip 44 may be include a single MEMS element 12.

The chip 54 may further include a coating 18 that is deposited on themain surface 11 of the substrate 10 at a region that surrounds the MEMSelements 12. The region at which the coating 18 is provided may belocated between an outer MEMS element 12 and one or more trenches 16 orbetween an outer MEMS element 12 and another region of the chip 54(e.g., a bond pad). The region at which the coating 18 is provided maybe provided at or in proximity to an inner edge of one or more trenches16 in order to prevent the protective material 13 from entering the oneor more trenches 16. The coating 18 may have a selective coatingproperty or composition (e.g., a hydrophobic material) that repels theprotective material 13. Thus, the coating 18 may be configured toconfine the protective material 13 inside the region and/or prevent theprotective material 13 from flowing into a trench 16 or other part ofthe chip 54.

In addition, a backside cavity 19 may be formed at the backside of thesubstrate 10 as an additional stress-decoupling feature that isintegrally formed with the one or more trenches 16.

FIG. 6A shows a cross-sectional diagram of still another chip 64according to one or more embodiments. The chip 64 includes a substrate10 having a main surface 11 and multiple MEMS elements 12 providedthereon. It will be appreciated that, while multiple MEMS elements 12are shown, the chip 34 may be include a single MEMS element 12.

The chip 64 further includes a stress-decoupling feature made of one ormore deep trenches 16 (i.e., one or more stress-decoupling trenches).

In this implementation, droplets of protective material 13 are dispensedand cured immediately right after finalization of the wafer and prior toa preassembly process (i.e., dicing process). In order to performfurther processing (e.g., lamination in preassembly), it may benecessary to cover the protective material 13 with a lid 61 that coversthe main surface 11 of the chip 64, as well as the protective material13. The lid 61 may be a pre-structured silicon or glass wafer or a lidconstruction made of SU-8 photoresist or a foil.

In order to achieve a pressure coupling between a MEMS element and itssurrounding (e.g., the chip), the lid 61 includes openings 62 formed viaan etch process, grinding or laser. The openings 62 allow the lid 61 tobe pressure coupled to the chip 64 via, for example, a vacuum seal.Alternatively, for products with a stress decoupling structure (e.g.,trenches 16) with backside cavity 19, the openings 62 may be absent fromthe lid 61 and a pressure coupling between the lid 61 and the chip 64can be achieved via the trenches 16. The lid 61 may remain closed untilthe end of the assembly process. An encapsulation of the MEMS element 12with an integrated gel droplet of protective material 13 may simplifythe mold process in the assembly process.

FIG. 6B shows a plan view of the lid 61 shown in FIG. 6A according toone or more embodiments. In particular, as described in FIG. 6A, the lid61 may include openings 62 that are used pressure couple the lid 61 tothe chip 64.

FIG. 7 shows a cross-sectional diagram of still another chip 74according to one or more embodiments. The features of chip 74 aresimilar to the features of chip 44 shown in FIG. 4, except chip 74 doesnot include stress-decoupling trenches 16 and shows bond pads 71connected to bond wires 72.

Even in a case without trenches 16, a stop frame 17 can be advantageous,where the bond pads 71 are protected from gel bleeding. This is not onlyimportant for the application of the protective material 13 before thewire bonding but also when protective material 13 is deposited afterwire bonding. For the subsequent back-end processes, adhesion issuesduring polymer encapsulation (e.g. by mold compound or coating) can beavoided caused by gel residues from the protective material 13 on thechip main surface 11. These issues might occur when the encapsulationlands on gel residues instead of the pure/clean chip.

FIG. 8 shows a cross-sectional diagram of a package 80 according to oneor more embodiments. The package 80 includes a chip (e.g., any one ofthe chips described above) that is encapsulated by an encapsulationmaterial 81 (e.g., a mold compound or coating). The chip includes aprotective material 13 and a stop frame 17 as permanent features of thepackage (i.e., the end packaged device). The package 80 further includesan opening 82 such that the MEMS element 12 is able to measure aphysical quantity, for example, a pressure of a pressure inducingentity.

Thus, during a package assembly process, a chip may be mounted to apackage (e.g., partially encapsulated by encapsulation material 81),where the chip includes at least one MEMS element 12 and that furtherincludes the protective material 13 disposed over the sensitive area ofthe at least one MEMS element 12. As described above, the protectivematerial 13 is configured to permit a sensor functionality of the atleast one MEMS element 12.

FIG. 9 shows a cross-sectional diagram of a package 90 according to oneor more embodiments. The package 90 is similar to package 80 shown inFIG. 8, with the addition of a seal ring 91. The seal ring 91 is a framestructure that encircles or at least partially encircles the stop frame17 and the MEMS element 12. Additionally, the seal ring 91 is spacedapart from the stop frame 17 towards the periphery of the substrate 10,and may be formed on an opposite side of the deep trench(es) 16 (i.e.,one or more stress-decoupling trenches) relative to the stop frame 17.For example, the seal ring 91 may be arranged on the substrate 10,between the stop frame 17 and a bond pad 71. In the case a deep trench16 is present, the seal ring 91 may be arranged on the substrate 10,between the deep trench 16 and the bond pad 71.

The seal ring 91 may be formed with a same material as the material ofthe stop frame 17, and may be formed during a same processing step asthe stop frame. Thus, the seal ring 91 and the stop frame may be formedsimultaneously or substantially simultaneously during a processing step.Specifically, the seal ring 91 is formed prior to applying theencapsulation material 81 (e.g., a mold compound or coating) duringassembly.

The seal ring 91 may facilitate use of a mold tool that is configured toapply the encapsulation material 81 to form the package. For example, amold tool (not shown) may be placed on the sealing frame, and mold isattached on everything that is outside of the seal ring 91.

In view of the above, a protective material 13 is provided as apermanent protective material that is deposited in between a front endprocess and a preassembly process or between the preassembly process andthe package assembly such that one or more MEMS elements 12 can beprotected from particles and humidity. Furthermore, the protectivematerial 13 is made of a material that grants full sensor functionalityof the MEMS element, including mechanical functionality and electricalfunctionality, while sealing an entire surface of the MEMS element.

More particularly, the protective material permits full sensorfunctionality of the MEMS element, including mechanical functionalityand electrical functionality, while sealing an entire surface of theMEMS element. Even more particularly, the protective material isconfigured such that no functionality of the MEMS element is impeded bythe protective material.

By ensuring that the functionality of the MEMS element 12 remainsintact, the protective material 13 may be deposited onto the MEMSelement 12 as a permanent material at an early stage of the chipfabrication process. Thus, the MEMS element 12 may already be configuredin an operable state (e.g., a final operable state) at the time theprotective material 13 is deposited onto the MEMS element 12, and theprotective material 13 may remain completely intact after deposition,including throughout the assembly process, such that it remains afeature in the final packaged product.

Although embodiments described herein relate to MEMS pressure sensors,it is to be understood that other implementations may include othertypes of pressure sensors or other types of MEMS devices or MEMSelements. In addition, although some aspects have been described in thecontext of an apparatus, it is clear that these aspects also represent adescription of the corresponding method, where a block or devicecorresponds to a method step or a feature of a method step. Analogously,aspects described in the context of a method step also represent adescription of a corresponding block or item or feature of acorresponding apparatus. Some or all of the method steps may be executedby (or using) a hardware apparatus, like for example, a microprocessor,a programmable computer or an electronic circuit. In some embodiments,some one or more of the method steps may be executed by such anapparatus.

Depending on certain implementation requirements, embodiments providedherein can be implemented in hardware or in software. The implementationcan be performed using a digital storage medium, for example a floppydisk, a DVD, a Blue-Ray, a CD, a ROM, a PROM, an EPROM, an EEPROM or aFLASH memory, having electronically readable control signals storedthereon, which cooperate (or are capable of cooperating) with aprogrammable computer system such that the respective method isperformed. Therefore, the digital storage medium may be computerreadable.

Instructions may be executed by one or more processors, such as one ormore central processing units (CPU), digital signal processors (DSPs),general purpose microprocessors, application specific integratedcircuits (ASICs), field programmable logic arrays (FPGAs), or otherequivalent integrated or discrete logic circuitry. Accordingly, the term“processor,” as used herein refers to any of the foregoing structures orany other structure suitable for implementation of the techniquesdescribed herein. In addition, in some aspects, the functionalitydescribed herein may be provided within dedicated hardware and/orsoftware modules. Also, the techniques could be fully implemented in oneor more circuits or logic elements.

The above described example embodiments that are merely illustrative. Itis understood that modifications and variations of the arrangements andthe details described herein will be apparent to others skilled in theart. It is the intent, therefore, to be limited only by the scope of theimpending patent claims and not by the specific details presented by wayof description and explanation of the embodiments herein.

1. A method of protecting a microelectromechanical systems (MEMS) element, comprising: providing at least one MEMS element, comprising a sensitive area, on a substrate; depositing, prior to a package assembly process, a protective material over the sensitive area of the at least one MEMS element such that the sensitive area of at least one MEMS element is sealed from an external environment, wherein the protective material permits a sensor functionality of the at least one MEMS element; forming at least one stop frame on the substrate at a region that surrounds the at least one MEMS element, wherein the at least one stop frame is configured to confine the protective material inside the region curing the protective material; and removing the at least one stop frame subsequent to curing the protective material.
 2. The method of claim 1, further comprising: separating a portion of the substrate that includes the at least one MEMS element to form a chip, wherein the chip includes at least one stress-decoupling trench laterally spaced from the at least one MEMS element and extending into the substrate, and the protective material is confined to an area within a region defined by the at least one stress-decoupling trench.
 3. (canceled)
 4. The method of claim 1, wherein the at least one stop frame comprises imide, SU-8, or silicone, each having a higher degree of elastic modulus than the protective material.
 5. (canceled)
 6. The method of claim 1, further comprising: separating a portion of the substrate that includes the at least one MEMS element to form a chip, wherein the chip includes at least one stress-decoupling trench at an edge of the region such that the at least one stop frame is formed proximate to the at least one stress-decoupling trench and is configured to prevent the protective material from entering the at least one stress-decoupling trench.
 7. The method of claim 1, further comprising: depositing a coating on the substrate at a region that surrounds the at least one MEMS element, wherein the coating is configured to confine the protective material inside the region.
 8. The method of claim 1, further comprising: performing the package assembly process, including mounting a chip to a package, wherein the chip includes a portion of the substrate that includes the at least one MEMS element and that further includes the protective material disposed over the sensitive area of the at least one MEMS element.
 9. The method of claim 1, wherein depositing the protective material comprises: depositing the protective material as a locally defined droplet confined to a local region of the substrate that surrounds the at least one MEMS element.
 10. The method of claim 9, wherein the protective material is deposited using inkjet printing or micro dispensing.
 11. The method of claim 1, wherein each of the at least one MEMS element is a pressure sensor.
 12. The method of claim 1, wherein the protective material is a temperature hardening gel or a ultraviolet (UV) hardening gel.
 13. The method of claim 1, wherein protective material permits full sensor functionality of the MEMS element, including mechanical functionality and electrical functionality, while sealing an entire surface of the at least one MEMS element.
 14. The method of claim 1, wherein the protective material is a permanent protective material deposited in between a front end process and a preassembly process or between the preassembly process and the package assembly process.
 15. A semiconductor device comprising: a semiconductor chip comprising: a substrate; at least one microelectromechanical systems (MEMS) element, comprising a sensitive area, disposed at a surface of the substrate; and a protective material disposed over the sensitive area of the at least one MEMS element such that the sensitive area of at least one MEMS element is sealed from an external environment, wherein the protective material is configured to permit a sensor functionality of the at least one MEMS element; a package to which the semiconductor chip is mounted, wherein the package includes encapsulation material that is excluded from a first region, the first region extending over the sensitive area of the at least one MEMS element; at least one stress-decoupling trench laterally spaced from the at least one MEMS element and extending into the substrate, and the protective material is confined to an area within a region defined by the at least one stress-decoupling trench, wherein the at least one stress-decoupling trench defines an inside region of the surface of the substrate and a peripheral region of the surface of the substrate, and the encapsulation material is attached to the surface of the substrate at the peripheral region, and the first region is defined at least by the inside region.
 16. (canceled)
 17. The semiconductor device of claim 15, wherein the semiconductor chip further comprises: at least one stop frame disposed on the surface of the substrate at a second region, the second region surrounding the at least one MEMS element, wherein the at least one stop frame is configured to confine the protective material inside the second region.
 18. The semiconductor device of claim 17, wherein the at least one stop frame comprises imide, SU-8, or silicone, each having a higher degree of elastic modulus than the protective material.
 19. The semiconductor device of claim 17, wherein: the at least one stress-decoupling trench is at an edge of the second region such that the at least one stop frame is formed proximate to the at least one stress-decoupling trench and is configured to prevent the protective material from entering the at least one stress-decoupling trench.
 20. The semiconductor device of claim 15, wherein: each of the at least one MEMS element is a pressure sensor, the protective material is a locally defined droplet confined to a local region of the substrate that surrounds the at least one MEMS element, and the protective material permits full sensor functionality of the MEMS element, including mechanical functionality and electrical functionality, while sealing an entire surface of the at least one MEMS element.
 21. (canceled)
 22. A semiconductor device comprising: a semiconductor chip comprising: a substrate; at least one microelectromechanical systems (MEMS) element, comprising a sensitive area, disposed at a surface of the substrate; and a protective material disposed over the sensitive area of the at least one MEMS element such that the sensitive area of at least one MEMS element is sealed from an external environment, wherein the protective material is configured to permit a sensor functionality of the at least one MEMS element; a package to which the semiconductor chip is mounted, wherein the package includes encapsulation material that is excluded from a first region, the first region extending over the sensitive area of the at least one MEMS element; at least one stop frame disposed on the surface of the substrate at a second region, the second region surrounding the at least one MEMS element, wherein the at least one stop frame is configured to confine the protective material inside the second region; and a seal ring disposed on the surface of the substrate at a third region, the third region spaced apart from and surrounding the at least one stop frame, wherein the encapsulation material is attached to the surface of the substrate peripheral to the third region and is excluded from the surface of the substrate internal to the third region.
 23. The semiconductor device of claim 22, wherein the encapsulation material is disposed onto the seal ring.
 24. (canceled) 